Button assembling device and method

ABSTRACT

A device is disclosed for assembling the head and tab of a tufting button wherein the head has an opening on one side thereof and the tab has an elongated connecting end whose length is greater than the diameter of the button opening. The device, which automatically inserts the tab&#39;&#39;s connecting end in the hollow button head includes a recessed support block for supporting the button head on the side thereof opposite its opening and an elongated insertion rod operatively associated with the support block for movement between first and second positions with respect thereto. In its first position the insertion rod is located at a point remote from the support block and positioning of the cloth tab&#39;&#39;s connecting end within the opening. The second position of the rod is selected so that the rod will extend through the opening of a button positioned on the support means at an angle to the plane of the opening. As a result, when the insertion rod is moved from its first to its second position, the rod engages the cloth tab connecting end, which is partially located within the opening of the button on the support block, and urges the connecting end into the opening to complete the tufting button without damage to either the connecting end or to the button itself.

Barabas 3,789,496 Feb. 5, 1974 BUTTON ASSEMBLING DEVICE AND METHOD [75] Inventor: Andrew A. Barabas, Danbury,

Conn.

[73] Assignee: Castro Convertible Corporation,

New Hyde Park, NY.

[22] Filed: July 11, 1972 [21] Appl. No.: 270,665

{52] U.S. Cl 29/453, 29/235, 29/267, 227/156 [51] Int. Cl B23p 11/02 [58] Field of Search..... 29/450, 267, 453, 235, 512; 227/156; 24/90 B [56] References Cited UNITED STATES PATENTS 1,482,127 1/1924 Glick 1. 29/267 1,884,155 10/1932 Oestnaes et al.... 29/453 2,361,688 10/1944 Huclster 29/512 2,591,203 4/1952 Schmalz 1 29/453 UX 2,762,160 9/1956 Carrick et a1 227/156 Primary ExaminerChar1ie T. Moon Attorney, Agent, or Firm-Curtis, Morris 8L Safford [57] ABSTRACT A device is disclosed for assembling the head and tab of a tufting button wherein the head has an opening on one side thereof and the tab has an elongated connecting end whose length is greater than the diameter of the button opening. The device, which automatically inserts the tabs connecting end in the hollow button head includes a recessed support block for supporting the button head on the side thereof opposite its opening and an elongated insertion rod operatively associated with the support block for movement between first and second positions with respect thereto. In its first position the insertion rod is located at a point remote from the support block and positioning of the cloth tabs connecting end within the opening. The second position of the rod is selected so that the rod will extend through the opening of a button positioned on the support means at an angle to the plane of the opening. As a result, when the insertion rod is moved from its first to its second position, the rod engages the cloth tab connecting end, which is partially located within the opening of the button on the support block, and urges the connecting end into the opening to complete the tufting button without damage to either the connecting end or to the button itself.

ll Claims, 5 Drawing Figures Patented Feb. 5, 1974 BUTTON ASSEMBLING DEVICE AND METHOD The present invention relates to tufting buttons and more particularly to a device for inserting the connecting end of a cloth tab in a hollow tufting button head.

Tufting buttons are well known in their use in the manufacture of tufted stuffed furniture, panels, and other similar items. Such buttons generally include a hollow head and an elongated tab connected to the back of the button head, i.e., to the side thereof placed against the article to be tufted. In the tufted article this tab is inserted through the fabric and secured at its free end to the rear of the article in order to form a depression in the exposed surface of the article.

One known type of tufting button utilizes a cloth tab having a reinforced connecting end which is connected to the hollow button head by insertion through an opening in the back of the head. The free end of the tab is also reinforced and generally has an elongated metal rod or the like which engages the back of the article being tufted in order to hold the button securely in position in the completed article.

The button heads and cloth tab of this type of tufting button are often separately supplied by the button manufacturer so that the manufacturer of the tufted fumiture or panels must connect the tab to the button prior to use in his product. Typically, the reinforced connecting end of the cloth tab is inserted in the opening of the tufting button and manually pushed through the opening. In order for the connecting end of the tab to remain in the button head, this end is formed with a length that is larger than the diameter of the opening in the button s head so that once the end is in the head, it cannot be pulled out. Because of the relative dimensions of the connecting end and the diameter of the opening in the buttons head, it is relatively difficult to insert the connecting end of the tab through the opening in the button. Hertofore, this process has been performed by hand with the individual performing the operation holding the button head in one hand, placing the connecting end through the opening as far as possible with the other hand, and then using a can opener, screw driver, or the like to push the tabs. connecting end through the opening in the head.

This manual operation has several obvious disadvantages. For example, it is both time consuming and dangerous for the operator since the can opener or screw driver used in this operation often slips in the hands of the operator, causing injury to her. In addition to possible injury, such slippage of the tool used to insert the tabs connecting end in the buttons head can damage the button itself. This often occurs where a cloth covered tufting button head is utilized.

Accordingly, it is an object of the present inventio to assemble a tufting buttons head and tab.

Another object of the present invention is to insert the connecting end of a cloth tab in a hollow tufting button head by an apparatus which is relatively simple and inexpensive in construction.

Yet another object of the present invention is to insert the connecting end of a cloth tufting tab in the hollow head of a tufting button by a device which is relatively simple to operate and which eliminates the need for the operator to manually hold the tufting button or insertion tool.

In accordance with an aspect of the present invention a device is provided for assembling a tufting button wherein the button includes a hollow head having an opening on one side thereof and a cloth tab having a reinforced elongated connecting end, having a length that is greater than the diameter of the opening, which is to be inserted in the hollow head through the opening therein. The device includes a base plate and a button support block mounted on the base having a recessed upper surface which is adapted to support a hollow button head on the side thereof opposite its opening so that the opening is directed generally upwardly. A lever arm, pivotally mounted on the base for pivotal movement above the support block, has an elongated rod mounted therein which extends generally perpendicularly to the arm with the free end thereof directed generally towards the base plate. This rod is positioned on the lever arm to enter the opening in a button supported on the support block at an angle to the plane of the buttons opening.

The lever arm is biased, by a compression spring, opeatively connected between the base plate and the lever arm, to a first position wherein the elongated rod in the arm is remote from the support block in order to permit placement of a button head on the support block and positioning of a cloth tab connecting end partially within the button opening. As a result of this construction, upon pivotal movement of the lever arm towards the support block, the elongated rod mounted in the arm engages the connecting end of the cloth tab and urges that end through the opening of the hollow button head to complete the tufting button. This operation is performed without any damage to or destruction of the connecting end or the button head.

The above, and other objects, features and advantages of this invention will be apparent in the following detailed description of an illustrative embodiment thereof which is to be read in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a device, constructed in accordance with an embodiment of the present invention, for inserting a cloth tab in a hollow tufting button head;

FIG. 2 is an exploded perspective view of the components of a tufting button to be assembled by the apparatus of FIG. 1;

FIG. 3 is a perspective view of a tufting button head completed prior to insertion in the apparatus of FIG. 1;

FIG. 4 is a partial side sectional view of the apparatus of FIG. 1 illustrating the engagement of the insertion rod and the connecting end of the cloth tab as movement of the tab into the hollow tufting button is'initiated; and

FIG. 5 is a partial side sectional view, similar to FIG. 4, illustrating the completed insertion of the connecting end of the tab in the hollow button head.

Referring now to the drawing in detail, and initially to FIG. 1 thereof, it is seen that a device 10 for assembling a tufting button, includes a base 12 and a button support block 14 mounted thereon. Support block 14 is secured to base 12 in a predetermined position and in any convenient manner, such as for example, by screws or an adhesive and the like. The block has a recessed upper surface 16 in which the button head to be used in the completed tufting button assembly is supported, as more fully described hereinafter.

A lever 18 is pivotally mounted on base 12 by a hinge 20, or the like which is operatively secured to the lever and the base in any convenient manner. This lever has a tapered free end portion 20 which is manually engageable to permit the operator to pivot the lever between two extreme positions during the operation of the device. A compression spring 22 biases lever 18 into its first position, illustrated in FIG. I, and is operatively connected at its free ends 24, 26 to lever 18 and base 12 respectively. In this position of the lever, support block 14 and its recessed surface 16 are fully exposed to permit insertion of a tufting button in the recess as described hereinafter.

Lever 18 is provided with an elongated insertion rod 28 which is rigidly mounted therein in a predetermined position so that the rod is located above recess 16. This rod can be provided in any convenient form and preferably is an elongated bolt having a threaded or serrated surface for cooperation with the cloth tab, as will be presently described. As seen in FIG. 4, insertion rod 28 extends generally perpendicularly through a bore 30 in lever 18 and is locked in position by a lock nut 32 which is threadedly engaged with the bolt and has a plurality of studs or projections 34 which engage the lower surface 36 f the lever to prevent rotation thereof.

Referring now to FIG. 2 of the drawing, the various components of one type of tufting button assembly 40 are illustrated. This button assembly includes a generally dish shaped cap portion 42, forming the front of the button, and a rear dish shaped cap 44 which is adapted to be inserted in and frictionally engaged with cap portion 42 in the conventional manner, so as to form a completed button head H. In one embodiment of the invention cap portion 42 is provided with a cloth or fabric cover 46 which covers the exterior surface of the cap member and is folded over its edges 48 into the interior thereof. The folded edges 50 of the pieces of cloth 40 are engaged by the edge 52 of rear cap 44 upon insertion of the rear cap in cap 42 and is maintained in a fixed position with respect to the cap 42 by this engagement. This tufting button head assembly is of conventional and well known construction.

The assembly of the tufting head components 42, 44 and 46 is normally performed by the button manufacturer, with the completed button supplied to the manufacturer of tufted furniture or panels and the like. FIG. 3 illustrates the configuration of the assembled button head H.

Tufting button 40 is typically completed by the provision of a cloth tab 56 which includes a connecting end 58 and a rear or stop end 60. Ends 58 and 60 are formed in a similar and conventional manner with a metal semi-cylindrical core 62 having a central elongated slot 64 therein. The fabric at the ends of the tab 56 is wrapped about the core 62, with portions thereof inserted through slit 64, and the core being crimped about the portions of the tab inserted through slit 64 so as to frictionally maintain engagement with the fabric and prevent loosening of the fabric from about the core. The core 62 at connecting end 58 of the tufting tab is substantially smaller than the core 62 at the stop end 60 and normally is fully enclosed within the fabric forming the tab.

In order to assemble button head H and tab 56, the

the relatively rigid connecting end 58 of the tab connecting end 58 of the tab is inserted through an opening 66 formed in the rear cap 44 of head H. As dethrough the opening 66 of head H into the hollow interior thereof. This procedure is relatively difficult because of the fact that the length of connecting end 58 must be greater than the diameter of opening 66 so that after the connecting end is inserted within head I-I, it cannot be pulled therefrom.

While head H has been described as a two piece member, it is to be understood that it may also be provided as a one piece member having the aperture 66 formed in one side thereof. In either case the problems of insertion of connection end 58 in the aperture 66 are the same.

In accordance with the present invention, the prior procedure of manually holding head H and inserting connecting end 58 of tab 56 in aperture 66 by the use of a manually held implement is eliminated. Referring again to FIG. 4 of the drawing it is seen that in the operation of the present invention the hollow button head H is seated or supported in recess 16 of block 14. The connecting end 58 of tab 56 is then manually placed in aperture 66 at an angle to the plane of the aperture, in the manner illustrated. With the tufting button partially assembled in this manner lever 18 is operated by pivoting it towards the block 14 so that the free end 68 of elongated rod 28 engages connecting end 58 of the tab.

Because of the mounting of rod 58 perpendicularly to lever 18, the rod approaches opening 66 of head H at an angle to the plane of the opening and at a slight angle to the connecting end 58. Further pivotal movement of lever 18 causes rod 28 to urge connecting end 58 through opening 66 into the hollow head H. Ultimately, connecting end 58 is pushed completely into hollow head H in the manner illustrated in FIG. 5. In this position the end 68 of rod 28 is located within the hollow head and seats the end 58 of tab 56 therein. Because the connecting end 58 has a larger length than the diameter of opening 66, the tab cannot be pulled out of the head. At this pointlever 18 is released and automatically returns to its first position under the influence of spring 22 to permit removal of the assembled button and positioning of the next button for subsequent assembly.

As mentioned above, in the preferred embodiment, insertion rod 28 is an elongated bolt with the threads thereon forming the serrated surface. This surface frictionally engages the cloth material covering the central supporting core 62 of end 58 to assure positive contact therebetween and proper application of the insertion forces through lever 18 to connecting end 58, so that no slippage between the rod and the connecting end occurs.

Preferably, in preparing components H and 56 for assembly in support block 14, connecting end 58 of tab 56 is placed so that it extends along a line which is perpendicular to the pivotal motion of the lever 18, and which is in the same plane as the longitudinal axis of bolt 28. While this specific placement facilitates insertion of the connecting end 58 in head I-I, because it assures proper contact of the rod 28 with the connecting end and the application of the insertion forces from the lever generally along the axis of the insertion end, the

end 58 can be placed in other positions on either side of this line.

In any case, the insertion of connecting end 58 in head H is accomplished without bending or damage of the connecting end 58 or any detriment to its later function of maintaining the assembled configuration'of tab 56 and head H. In addition, the components 42 and 44 of the head itself are undamaged by the insertion of connecting end 58 and damage to the fabric 46 covering the head is prevented.

As described above, the completed tufting button assembly is used in a conventional manner to manufacture tufted furniture or panels which are stuffed with a resilient material and covered with a flexible fabric. Button head H is positioned with its rear surface 44 against the fabric of the piece of furniture with tab 56 and stop end 60 inserted through the fabric. The stop end 60 is then engaged with the back of the furniture or panel so that head H acts to depress the stuffing of the furniture to form a tufted appearance.

Accordingly, it is seen that a relatively simple device is provided for completing assembly of a tufting button which eliminates the manual operations heretofore required. By the present invention the tufting button is readily assembled without possible injury to the operator or damage to the button head itself.

Wjile the illustrative embodiment of the device has been described as a manually operated system, it is to be understood that the principles of the invention can be used in an automatic system wherein lever 18 is operated by a pneumatic or hydraulic device, motor and the like, upon depression of an appropriate control button. In addition, the movement of rod 28 can be controlled in a manner other than the lever assembly illustrated. For example, the bolt can be mounted at an angle in a flat plate, with the plate depressed in a vertical direction by a ram or the like, so that bolt 28 engages the connecting end 58 of the tab at an angle in the manner similar to that illustrated in FIG. 4.

Although an illustrative embodiment of the present invention has been described herein in detail, with reference to the accompanying drawing, it is to be understood that the invention is not limited to that precise embodiment and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of this invention.

What is claimed is:

1. A device for assembling a tufting button wherein said button includes a hollow head having an opening on one side thereof and a tab having an elongated connecting end whose length is greater than the diameter of the opening in said button, said device comprising means for supporting a button head on the side thereof opposite said opening, an elongated rod operatively associated with said support means, and means for moving said rod between first and second positions with respect to said support means, wherein, said rod is located remote from said support means in the first position thereof to permit insertion of a button head on said support means and positioning of a tab connecting and partially in said button head opening and said rod is located within the opening of a button head on said support means in the second position thereof at an acute angle to the plane of said opening and in engagement with a side portion of the tab in said head opening at an acute angle to said tab, whereby said rod engages a tab connecting end, located partially in the opening of a head on said support means at an acute angle as said rod approaches its second position and urges said connecting end angularly into said opening to complete said tufting button.

2. The device as defined in claim 1 wherein said supporting means comprises a support block having a recess therein in which said button head is seated.

3. The device as defined in claim 2 wherein said rod has a serrated surface adapted to engage a tab connecting end located in a button head opening.

4. The device as defined in claim 3 wherein said rod is spring biased into said first position.

5. A device for assembling a tufting button wherein said button includes a hollow head having an opening on one side thereof and a cloth tab having a reinforced elongated connecting end adapted to be inserted in said hollow head through said opening and whose length is greater than the diameter of the opening in said button, said device comprising, a base, a button support block mounted on said base and having a recessed upper surface adapted to support a button head on the side thereof opposite its opening, a lever arm pivotally mounted on said base, an elongated rod mounted in said lever arm and extending generally perpendicularly thereto, said rod having a free end directed generally towards said base and being positioned in said lever arm to enter the opening in a button head supported on said block at an angle to the plane of said opening, spring means biasing said lever arm to a first position wherein said rod is remote from said block to permit insertion of a button head thereon and positioning of a cloth tab connecting end partially in the button head opening, whereby,-upon pivotal movement of said lever towards said block, said rod engages said tab connecting end and urges said end through said opening into said head to complete said tufting button.

6. The device as defined in claim 5 wherein said elongated rod has a serrated surface adapted to engage said cloth tab connecting end.

7. The device as defined in claim 6 wherein said elongated rod is a screw and said serrates surface is provided by the screw threads thereof.

8. The device as defined in claim 7 including a lock nut operatively engaged between said screw and said lever arm for preventing rotation of said screw.

9. The device as defined in claim 5 wherein said spring means comprises a coil spring operatively engaged between said base and said lever arm.

10. The method of inserting the reinforced elongated connecting end of a cloth tab in an opening in one side of a hollow button head to form a completed tufting button, said method comprising, the steps of supporting a hollow button head in a support block on the side thereof opposite its opening to expose said opening, inserting the connecting end of a cloth tab in said opening at an angle to the plane thereof, engaging a side of said tab with an elongated serrated rod at an acute angle to the tab and in a plane extending generally perpendicularly to said button head opening and urging said rod angularly into said hollow button head at an acute angle to the plane of said opening whereby said rod forces said connecting tab into said button to complete said tufting button without damage to said tab or said head.

11. The method as defined in claim 10 including the step of pivotally mounting said elongated rod for movement between said first and second positions with respect to said block, said first position being remote from said block and said second position being adjacent said block when said rod is inserted in said open- 

1. A device for assembling a tufting button wherein said button includes a hollow head having an opening on one side thereof and a tab having an elongated connecting end whose length is greater than the diameter of the opening in said button, said device comprising means for supporting a button head on the side thereof opposite said opening, an elongated rod operatively associated with said support means, and means for moving said rod between first and second positions with respect to said support means, wherein, said rod is located remote from said support means in the first position thereof to permit insertion of a button head on said support means and positioning of a tab connecting and partially in said button head opening and said rod is located within the opening of a button head on said support means in the second position thereof at an acute angle to the plane of said opening and in engagement with a side portion of the tab in said head opening at an acute angle to said tab, whereby said rod engages a tab connecting end, located partially in the opening of a head on said support means at an acute angle as said rod approaches its second position and urges said connecting end angularly into said opening to complete said tufting button.
 2. The device as defined in claim 1 wherein said supporting means comprises a support block having a recess therein in which said button head is seated.
 3. The device as defined in claim 2 wherein said rod has a serrated surface adapted to engage a tab connecting end located in a button head opening.
 4. The device as defined in claim 3 wherein said rod is spring biased into said first position.
 5. A device for assembling a tufting button wherein said button includes a hollow head having an opening on one side thereof and a cloth tab having a reinforced elongated connecting end adapted to be inserted in said hollow head through said opening and whose length is greater than the diameter of the opening in said button, said device comprising, a base, a button support block mounted on said base and having a recessed upper surface adapted to support a button hEad on the side thereof opposite its opening, a lever arm pivotally mounted on said base, an elongated rod mounted in said lever arm and extending generally perpendicularly thereto, said rod having a free end directed generally towards said base and being positioned in said lever arm to enter the opening in a button head supported on said block at an angle to the plane of said opening, spring means biasing said lever arm to a first position wherein said rod is remote from said block to permit insertion of a button head thereon and positioning of a cloth tab connecting end partially in the button head opening, whereby, upon pivotal movement of said lever towards said block, said rod engages said tab connecting end and urges said end through said opening into said head to complete said tufting button.
 6. The device as defined in claim 5 wherein said elongated rod has a serrated surface adapted to engage said cloth tab connecting end.
 7. The device as defined in claim 6 wherein said elongated rod is a screw and said serrates surface is provided by the screw threads thereof.
 8. The device as defined in claim 7 including a lock nut operatively engaged between said screw and said lever arm for preventing rotation of said screw.
 9. The device as defined in claim 5 wherein said spring means comprises a coil spring operatively engaged between said base and said lever arm.
 10. The method of inserting the reinforced elongated connecting end of a cloth tab in an opening in one side of a hollow button head to form a completed tufting button, said method comprising, the steps of supporting a hollow button head in a support block on the side thereof opposite its opening to expose said opening, inserting the connecting end of a cloth tab in said opening at an angle to the plane thereof, engaging a side of said tab with an elongated serrated rod at an acute angle to the tab and in a plane extending generally perpendicularly to said button head opening and urging said rod angularly into said hollow button head at an acute angle to the plane of said opening whereby said rod forces said connecting tab into said button to complete said tufting button without damage to said tab or said head.
 11. The method as defined in claim 10 including the step of pivotally mounting said elongated rod for movement between said first and second positions with respect to said block, said first position being remote from said block and said second position being adjacent said block when said rod is inserted in said opening. 